Modular, expandable, prefabricated chassis for electrical vehicle charging stations

Abstract

A modular, expandable, prefabricated chassis for EV charging stations useful in supporting a plurality of EVSE charging posts, including a support housing through which power and communications cabling is channeled, and a connection cabinet affixed to the support housing for receiving power from a utility, and disbursing it through the cabling. Also, a modular, portable EV charging station, including a chassis and a plurality of EVSE charging posts affixed to the support housing, wherein power cables, the electrical wire and the communications cabling from the support housing are electrically or communicatively coupled with the EVSE charging post. Also, a method of installing an EV charging station at a site, the method including the transport of a fully assembled EV charging station to a site, positioning the EV charging station on a solid pad provided at the site, and connecting utility lines to the connection cabinet of the EV charging station.

1 . A modular, expandable, prefabricated chassis for EV charging stations useful in supporting a plurality of EVSE charging posts, the chassis comprising:
 a support housing, the support housing presenting as an enclosed, modular, raised platform, with a plurality of EVSE charging post positions defined thereon, and a port at each said EVSE charging post position;   a connection cabinet affixed to the support housing, the connection cabinet having a master circuit breaker and electrical circuitry capable of receiving electricity from a power source, and distributing the electricity to a plurality of power supply cables and a plurality of electrical wires, wherein the connection cabinet further comprises communication cabling, and wherein the power supply cables, electrical wires and communication cabling are routed through the support housing to the EVSE charging post positions; and   a plurality of cable supports secured within or integral with an interior of the support structure, the cable supports facilitating and managing the routing of the power supply cables and the electrical wires through the support housing.   
     
     
         2 . The chassis of  claim 1 , wherein the support housing further comprises a plurality of internal lifting lugs secured to or integral with a wall of an exterior channel of the support housing, to support the cabling or the cable supports, and to provided additional support to the support housing and additional protection for the cabling or the cable supports. 
     
     
         3 . The chassis of  claim 1 , wherein the support housing comprises a plurality of connected elongated tubes with a rectangular cross-section, or a plurality of connected rectangular pads, or a connected combination of one or more elongated tubes with a rectangular cross section and one or more rectangular pads, and wherein the elongated tubes or the rectangular pads, or the elongated tubes and the rectangular pads, present with an open channel to facilitate the routing of the power supply cables and the electrical wires through the elongated tubes or the rectangular pads, or the elongated tubes and rectangular pads. 
     
     
         4 . The chassis of  claim 3 , wherein a top or side surface of the support housing has one or more apertures, and wherein one or more plates are removably secured to the support housing, covering the apertures. 
     
     
         5 . The chassis of  claim 1 , wherein a portion of the support housing is raised for purposes of accommodating the cables and the cable supports, while a lateral adjacent portion of the support housing has a lower profile, and wherein at least some of the EVSE charging post positions are positioned in the adjacent portion of the support housing. 
     
     
         6 . The chassis of  claim 3 , wherein at least one of the elongated tubes or the rectangular pads include a removable end cap to allow for future expansion of the chassis, which when removed expose a channel through which power supply cables and electrical wires may pass. 
     
     
         7 . The chassis of  claim 1 , wherein the support housing comprises one or more strong eye bolts positioned on posts, useful in lifting the chassis from a transportation vehicle and position it at a station site. 
     
     
         8 . A modular, portable EV charging station comprising:
 a chassis comprising:
 a support housing, the support housing presenting as an enclosed, modular, raised platform, with a plurality of EVSE charging post positions defined thereon, and a port at each said EVSE charging post position; 
 a connection cabinet affixed to the support housing, the connection cabinet having a master circuit breaker and electrical circuitry capable of receiving electricity from a power source, and distributing the electricity to a plurality of power supply cables and a plurality of electrical wires, wherein the connection cabinet further comprises communication cabling, and wherein the power supply cables, electrical wires and communication cabling are routed through the support housing to the EVSE charging post positions; and 
 a plurality of cable supports secured within or integral with an interior of the support structure, the cable supports facilitating and managing the routing of the power supply cables and the electrical wires through the support housing; and 
   a plurality of EVSE charging posts affixed to the support housing at one or more of the EVSE charging post positions, wherein the power cables, the electrical wire and the communications cabling are electrically or communicatively coupled with the EVSE charging post.   
     
     
         9 . The EV charging station of  claim 8 , wherein the support housing further comprises a plurality of internal lifting lugs secured to or integral with a wall of an exterior channel of the support housing, to support the cabling or the cable supports, and to provided additional support to the support housing and additional protection for the cabling or the cable supports. 
     
     
         10 . The EV charging station of  claim 8 , wherein the support housing comprises a plurality of connected elongated tubes with a rectangular cross-section, or a plurality of connected rectangular pads, or a connected combination of one or more elongated tubes with a rectangular cross section and one or more rectangular pads, and wherein the elongated tubes or the rectangular pads, or the elongated tubes and the rectangular pads, present with an open channel to facilitate the routing of the power supply cables and the electrical wires through the elongated tubes or the rectangular pads, or the elongated tubes and rectangular pads. 
     
     
         11 . The EV charging station of  claim 10 , wherein a top or side surface of the support housing has one or more apertures, and wherein one or more plates are removably secured to the support housing, covering the apertures. 
     
     
         12 . The EV charging station of  claim 8 , wherein a portion of the support housing is raised for purposes of accommodating the cables and the cable supports, while a lateral adjacent portion of the support housing has a lower profile, and wherein at least some of the EVSE charging post positions are positioned in the adjacent portion of the support housing. 
     
     
         13 . The EV charging station of  claim 10 , wherein at least one of the elongated tubes or the rectangular pads include a removable end cap to allow for future expansion of the chassis, which when removed expose a channel through which power supply cables and electrical wires may pass. 
     
     
         14 . The EV charging station of  claim 8 , wherein the support housing comprises one or more strong eye bolts positioned on posts, useful in lifting the chassis from a transportation vehicle and position it at a station site. 
     
     
         15 . The EV charging station of  claim 8 , wherein the support housing comprises a plurality of connected elongated tubes with a rectangular cross-section and a plurality of connected rectangular pads, wherein the elongated tubes and the rectangular pads present with an open channel to facilitate the routing of the power supply cables and the electrical wires through the elongated tubes and the rectangular pads, and wherein the plurality of EVSE charging posts include at least two different models of EVSE charging posts, a first model affixed to a rectangular pad, and a second model affixed to an elongated tube. 
     
     
         16 . A method of installing an EV charging station at a site, the method comprising the steps of:
 transporting an EV charging station to a site, the EV charging station comprising:
 a chassis comprising:
 a support housing, the support housing presenting as an enclosed, modular, raised platform, with a plurality of EVSE charging post positions defined thereon, and a port at each said EVSE charging post position; 
 a connection cabinet affixed to the support housing, the connection cabinet having a master circuit breaker and electrical circuitry capable of receiving electricity from a power source, and distributing the electricity to a plurality of power supply cables and a plurality of electrical wires, wherein the connection cabinet further comprises communication cabling, and wherein the power supply cables, electrical wires and communication cabling are routed through the support housing to the EVSE charging post positions; and 
 a plurality of cable supports secured within or integral with an interior of the support structure, the cable supports facilitating and managing the routing of the power supply cables and the electrical wires through the support housing; and 
 
 a plurality of EVSE charging posts affixed to the support housing at one or more of the EVSE charging post positions, wherein the power cables, the electrical wire and the communications cabling are electrically or communicatively coupled with the EVSE charging post; 
   positioning the EV charging station on a solid pad provided at the site; and   connecting utility lines to the connection cabinet of the chassis.   
     
     
         17 . The method of installing an EV charging station at a site as provided in  claim 16 , further comprising the step of leveling the station by means of one or more levelers. 
     
     
         18 . The method of installing an EV charging station at a site as provided in  claim 16 , wherein the support housing comprises a plurality of connected elongated tubes with a rectangular cross-section, or a plurality of connected rectangular pads, or a connected combination of one or more elongated tubes with a rectangular cross section and one or more rectangular pads, and wherein the elongated tubes or the rectangular pads, or the elongated tubes and the rectangular pads, present with an open channel to facilitate the routing of the power supply cables and the electrical wires through the elongated tubes or the rectangular pads, or the elongated tubes and rectangular pads. 
     
     
         19 . The method of installing an EV charging station at a site as provided in  claim 18 , wherein at least one of the elongated tubes or the rectangular pads include a removable end cap, and wherein at the site the end cap is removed, exposing a channel through which power supply cables and electrical wires may pass, and another elongated tube or rectangular pad is secured to the at least one of the elongated tubes or rectangular pads by means of an extender.